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CEMENT INDUSTRY

APPLICATION OF REFRACTORY MATERIALS

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DGC Refractories provides a comprehensive range of high-performance refractory materials specifically engineered for the cement industry. Our solutions are developed to withstand extreme heat, abrasive dust environments, and corrosive alkali vapours—maximising kiln uptime, thermal efficiency, and service life.

 

With over a century of industrial heritage and more than 60 years of applied expertise in refractories, we support cement producers with technical-grade materials suited for every zone of the pyroprocessing line.

  KEY    AREAS OF APPLICATION  

We supply engineered refractory solutions for all core equipment in the cement production process:

  • Rotary Kilns

  • Upper & Lower Transition Zones

  • Calcining Zones

  • Preheaters & Calciners

  • Kiln Hoods & Burner Zones

  • Tertiary Air Ducts (TADs)

  • Coolers

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  SHAPED REFRACTORY  

  MATERIALS  

  BASIC    REFRACTORIES  

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Engineered for durability under basic slag, alkali, and high-heat loads:

  • Magnesia Hercynite Bricks – Chromium-free, thermal shock-resistant

  • Magnesia Spinel Bricks – Excellent resistance to alkalis and thermal stress

  • Magnesia Chrome Bricks – High strength, corrosion resistance

  • Magnesia Ferrum Spinel Bricks – Enhanced iron slag resistance​

  • Magnesia Alumina Spinel Bricks – Stability under mechanical load and chemical attack

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  ALUMINA-SILICA    REFRACTORIES  

  • Silica Bricks – Refractoriness under load in preheater zones

  • First-Grade High Alumina Bricks – Strength and abrasion resistance

  • Anti-Spalling High Alumina Bricks – High thermal shock resistance

  • Alkali Resistant Bricks – For preheater linings and riser ducts

  • SiC-Mullite Andalusite Bricks – Strength under thermal cycling

  • Multilayer Mullite Bricks with Reduced Thermal Conductivity – Engineered to lower kiln shell temperatures by up to 80°C

Designed for alkali corrosion resistance and dimensional stability:

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  PERFORMANCE  

  HIGHLIGHTS  

Why cement producers choose DGC Refractories:

  OPERATIONAL CHALLENGE  

  • Shell temperature too high

  • Frequent brick replacement in UTZ/LTZ

  • Alkali attack in preheater and ductwork

  • Coating instability in burning zone

  • Mechanical wear near cooler bull nose

  DGC REFRACTORIES SOLUTION  

  • Low thermal conductivity mullite bricks reduce external temperatures by 50–80°C

  • Long-life multilayer systems designed for 12–15+ months service

  • Alkali-resistant bricks and coatings with proven chemical resistance

  • Magnesia-hercynite and ferrum spinel bricks with stable in-situ layer formation

  • High-strength alumina bricks with excellent abrasion resistance

All products undergo extensive QA/QC testing, including RUL, TSR, and chemical analysis, backed by third-party verification from CTC, CST, SGS or Bureau Veritas if required.

MATERIALS FOR

ENERGY SAVINGS

& EMISSIONS REDUCTION

DGC’s next-generation brick systems support the cement industry’s transition to more sustainable and energy-efficient production:

  • Lower thermal conductivity (1.6–2.4 W/m·K)

  • Reduced fuel consumption per ton of clinker (1.5–3 kg savings possible)

  • CO₂ emission reductions via improved insulation and longer service life

  • Improved kiln coating formation for enhanced heat retention and process stability

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Cement Industry
Application Guide

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